Double face connected carpet structure



J. SABBE."

DOUBLE FACE CONNECTED CARPET STRUCTURE June 27, 1967 2 Sheets-Sheet 1 Filed March 1, 1965 INVENTOR.

June 27, i fi'f J SAEBE E FACE CONNECTED CARPET STRUCTURE DOUBL 2 Sheets-$heet 2 Filed March 1, 1965 l9 20a 21a. 22a.

FIGS

IN VEN TOR.

United States Patent 3,327,738 DOUBLE FACE CONNECTED CARPET STRUCTURE Jan Sabbe, Courtrai, Belgium, assignor to Societe Librex Anstalt, Liechtensteinische Landesbank, Vaduz, Liechtenstein, a corporation of Liechtenstein Filed Mar. 1, 1965, Ser. No. 436,191 Claims priority, application France, Mar. 4, 1964, 18,364

3 Claims. (Cl. 139-398) The present invention relates to carpets and is particularly concerned with carpets or rugs such as are produced face to face and to a method of producing such carpets or rugs.

Such carpets may be woven face to face on a Jacquard carpet loom having one or two shuttles and with wovenin connecting yarns.

In known carpets woven on machines and by processes according to the present state of the art one weft pile yarn and on woven-in or binding weft yarn, or one weft pile yarn and two woven-in or binding weft yarns are used. With Jacquard mechanisms siutable for this weave the weft yarns are laid in the sheds in a repeating manner according to a sequence comprising an even number of picks.

It is one object of the present invention to provide carpets which are characterised by the fact that there are necessarily and successively in each fabric face component at least two weft pile yarns and one binding weft yarn for each repeat.

It is another object of the present invention to pro vide carpets, wherein the weaving pattern is obtained by inserting the pile-forming yarns alternately in the two fabric components and then a binding weft yarn in each component.

With these and other objects in view which will become apparent inthe following detailed description, the present invention will be clearly understood in connection with the accompanying drawings, in which:

FIGURE 1 illustrates in section the method of Weaving carpets according to the present invention showing in side view the pile, with two pile weft yarns for each binding weft yarn;

FIG. 2 illustrates a modification with a single connecting warp yarn;

FIG. 3 illustrates a modification with two binding yarns;

FIG. 4 illustrates a modification with two connecting warp yarns, and three weft pile yarns for each binding weft yarn; and

FIG. 5 illustrates a modification with two connecting warp yarns and four weft pile yarns for each binding weft yarns.

Referring now to the drawings, and in particular to FIG. 1, the pile warp yarns 1 and 2 are of different colors, undulatingly pass from one face 40 of the fabric to the other face 41, spaced therefrom, whenever the respective color is to appear in the finished carpet or remain idly incorporated in one fabric or the other as connecting yarns 3 and 4. The pile warp yarns 1 and 2 undulatingly interlace alternately pile weft yarns 5 and 6, at first opposed portions 42 and adjacent second opposed portions 43, respectively, of the faces 40 and 41 of each fabric forming first crests 1' and second crests 2, respectively, outwardly about the weft yarns 5 and 6; whereas the binding weft yarns 7 hold the connecting yarns 3 and 4 in position and the weft yarns 8 duplicate the pile weft yarns 5 and 6 or also hold the connecting yarns 3 or 4. The two fabrics are afterwards separated by a cutter blade diagrammatically illustrated at 9.

3',327738 Patented June 27, 1967 The weft picks repeat in the following sequence:

One weft yarn 5 for the upper fabric.

One Weft yarn 6 for the lower fabric. One weft yarn 5 for the upper fabric.

One weft yarn 6 for the lower fabric.

One binding yarn 8 for the upper fabric. One binding yarn 7 for the lower fabric.

This succession of picks is effected by means of a special Jacquard mechanism wherein the first four picks are produced by means of an appropriate punched card and the last two picks are produced by a plain card or by means of any other device actuating the warp yarns to allow the wefts to be laid as shown in FIG. 1 in a siX- step sequence.

It is also possible to obtain this pattern by means of a simple Jacquard mechanism which uses a different card for each yarn.

The advantages of this arrangement are that there is the largest possible number of pile picks in relation to the total number of yarns. The gain is 25% in respect of a plain fabric with single alternating yarns; the gain is 50% with respect to a pattern with two binding yarns.

The fabric structure according to the present invention can be bonded to a greater or lesser extent. A single bond is illustrated in FIG. 2. It comprises a taut warp yarn 10 and a crimped warp yarn 11 crossing two pile weft yarns side-by-side and in one direction and one binding weft yarn in the other direction.

A' double binding effect is illustrated in FIG. 3. It comprises a taut warp yarn 12 and two crimped warp yarns 13 and 14, the one crossing the odd-numbered pile weft yarns in one direction and the even-numbered pile weft yarns as well as the binding weft yarns in the outer direction, the other crossing the even-numbered pile weft yarns in one direction and the odd-numbered pile weft yarns as well as the binding weft yarns in the other direction.

Naturally other weaves can be devised without falling outside the scope of the invention provided that the ratio of two pile weft yarns to one binding Weft yarn is observed in respect to the six-step repeat described above. The same principle may be adopted for an eight-step repeat (FIG. 4) or a ten-step repeat (FIG. 5) which will give respectively three pile weft yarns 15, 16, 17 for one binding weft yarn 18, and four pile weft yarns 19, 20, 21, 22 for one binding weft yarn 23, The same applies for the bottom fabric where there are three pile weft yarns 15a, 16a, 17a for one binding weft yarn 18a (FIG. 4), and four pile weft yarns 19a, 20a, 21a, 22a, and one binding weft yarn 23a (FIG. 5

In the eight-step repeat the picks follow each other in the following order:

One weft yarn 15 for the upper fabric.

One weft yarn 15a for the lower fabric.

One weft yarn 16 for the upper fabric.

One weft yarn 16a for the lower fabric.

One weft yarn 17 for the upper fabric.

One Weft yarn 17a for the lower fabric.

One binding weft yarn 18 in the upper fabric. One binding weft yarn 18a in the lower fabric.

Similarly in the ten-step repeat the eight pile weft yarns follow each other alternately in the upper fabric and in the lower fabric and are followed by one binding weft yarn 23 in the upper fabric and one binding weft yarn 23a in the lower fabric.

In each case there is obviously provided in each fabric a binding of the wefts which is obtained by a taut yarn 24 (FIG. 4) and 25 (FIG. 5) and two crimped yarns 26, 27 (FIG. 4) and 28, 29 (FIG. 5).

Two pile warp yarns are shown at 30, 31 in FIG. 4 and at 32, 33 in FIG. 5 which remain woven in one or other fabric when they are not brought out to form the pile. While they are concealed they are connecting yarns and are held in position by the binding weft yarns 18, 18a, 23 or 23a.

It is possible to devise repeats with an even larger number of steps without departing from the scope of the invention but in this case practical difficulties may be encountered.

In the embodiments of FIGS. 4 and 5, there is an even higher proportion of weft pile yarns relatively to the total number of weft picks, which is the aim and the essential advantage of the invention.

While I have disclosed several embodiments of the present invention, it is to be understood that these embodiments are given by example only and not in a limiting sense, the scope of the present invention being determined by the objects and the claims.

What I claim is: 1. A double-faced connected carpet structure, having two spaced faces defining first opposed portions of the faces and second opposed portions of the faces, comprisa first pile warp yarn, a second pile warp yarn, said first pile warp yarn arranged to pass to said first opposed portions of the faces of said carpet in undulating fashion joining said first opposed portions of the faces together with said first pile warp yarn and forming a plurality of first crests adjacent said faces,

said second pile warp yarn disposed linearly along one of the faces at said first opposed positions and inward of said first crests adjacent said one face defining a second connecting yarn portion,

one first pile weft yarn in each of said first crests adjacent said faces,

said second pile warp yarn extends from said second connecting yarn portion to said second opposed portions of said faces of said carpet adjacent said first opposed portions of said faces of said carpet and arranged to pass to said second opposed portions of the faces in undulating fashion joining said second opposed portions of said faces together with said second pile warp yarn and forming a plurality of second crests adjacent said faces,

one second pile weft yarn within each of said second crests adjacent said faces,

said second connecting yarn portion being disposed inwardly of said first pile weft yarns adjacent said one face,

at least one first binding weft yarn Woven inwardly of said second connecting yarn portion between said first crests adjacent said one face to hold said second connecting yarn portion by and between said first pile weft yarns and said first binding weft yarn,

at least two of said first crests adjacent said one face for each said first binding weft yarn, and

a first crimp yarn interwoven adjacent said one face with at least one of said first pile weft yarns and said first binding weft yarn, and disposed outwardly relative said interwoven first pile weft yarn and inwardly relative said first binding weft yarn.

2. The double face connected carpet structure, as set forth in claim 1, wherein said first pile warp yarn extending from Said first opposed portions and disposed linearly along the other face of said second opposed portions inward of said second crests adjacent said other face defining a first connecting yarn portion,

said first connecting yarn portion being disposed inwardly of said second pile weft yarns adjacent said other face,

at least one second binding weft yarn woven inward of said first connecting yarn portion between said second crests adjacent said other face to hold said first connecting yarn portion by and between said second pile weft yarns, and said second binding weft yarns,

at least two of said second crests adjacent said other face for each said second binding Wef-t yarn, and

a second crimp yarn interwoven adjacent said other face with at least one of said second pile weft yarns and said second binding weft yarn, and disposed outwardly relative said interwoven second pile Weft yarn and inwardly relative said second weft yarn.

3. The double face connected carpet structure, as set forth in claim 2, further comprising a taut non-woven warp yarn inserted linearly adjacent each of said faces between said pile Weft yarns and said binding weft yarns.

References Cited UNITED STATES PATENTS 908,371 12/ 1908 Zimmermann 139-398 1,143,804 6/1915 Binz 139-398 1,795,157 3/1931 Zimmermann 139-398 FOREIGN PATENTS 569,205 7/ 1958 Belgium.

191,681 7/1888 France.

624,660 4/ 1927 France. 1,322,311 2/1963 France.

30,177 1897 Great Britain.

MERVIN STEIN, Primary Examiner.

I. KEE CHI, Assistant Examiner. 

1. A DOUBLE-FACED CONNECTION CARPET STRUCTURE, HAVING TWO FACES DEFINING FIRST OPPOSED PORTIONS OF THE FACES AND SECOND OPPOSED PORTIONS OF THE FACES, COMPRISING A FIRST PILE WARP YARN, A SECOND PILE WARP YARN, SAID FIRST PILE WARP YARN ARRANGED TO PASS TO SAID FIRST OPPOSED PORTIONS OF THE FACES OF SAID CARPET IN UNDULATING FASHION JOINING SAID FIRST OPPOSED PORTIONS OF THE FACES TOGETHER WITH SAID FIRST PILE WARP YARN AND FORMING A PLURALITY OF FIRST CRESTS ADJACENT SAID FACES, SAID SECOND PILE WARP YARN DISPOSED LINEARLY ALONG ONE OF THE FACES AT SAID FIRST OPPOSED POSITIONS AND INWARD OF SAID FIRST CRESTS ADJACENT SAID ONE FACE DEFINING A SECOND CONNECTING YARN PORTION, ONE FIRST PILE WEFT YARN IN EACH OF SAID FIRST CRESTS ADJACENT SAID FACES, SAID SECOND PILE WARP YARN EXTENDS FROM SAID SECOND CONNECTING YARN PORTION TO SAID SECOND OPPOSED PORTIONS OF SAID FACES OF SAID CARPET ADJACENT SAID FIRST OPPOSED PORTIONS OF SAID FACES OF SAID CARPET AND ARRANGED TO PASS TO SAID SECOND OPPOSED PORTIONS OF THE FACES IN UNDULATING FASHION JOINING SAID SECOND OPPOSED PORTIONS OF SAID FACES TOGETHER WITH SAID SECONE PILE WARP YARN AND FORMING A PLURALITY OF SECOND CRESTS ADJACENT SAID FACES, ONE SECOND PILE WEFT YARN WITHIN EACH OF SAID SECOND CRESTS ADJACENT SAID FACES, SAID SECOND CONNECTING YARN PORTION BEING DISPOSED INWARDLY OF SAID FIRST PILE WEFT YARNS ADJACENT SAID ONE FACE, AT LEAST ONE FIRST BINDING WEFT YARN WOVEN INWARDLY OF SAID SECOND CONNECTING YARN PORTION BETWEEN SAID FIRST CRESTS ADJACENT SAID ONE FACE TO HOLD SAID SECOND CONNECTING YARN PORTION BY AND BETWEEN SAID FIRST PILE WEFT YARNS AND SAID FIRST BINDING WEFT YARN, AT LEAST TWO OF SAID FIRST CRESTS ADJACENT SAID ONE FACE FOR EACH SAID FIRST BINDING WEFT YARN, AND A FIRST CRIMP YARN INTERWOVEN ADJACENT SAID ONE FACE WITH AT LEAST ONE OF SAID FIRST PILE WEFT YARNS AND SAID FIRST BINDING WEFT YARN, AND DISPOSED OUTWARDLY RELATIVE SAID INTERWOVEN FIRST PILE WEFT YARN AND INWARDLY RELATIVE SAID FIRST BINDING WEFT YARN. 